Ultrasonic acoustic emissions to detect substrate fracture

• US 8,281,661 B2
• Filed: 05/27/2010
• Issued: 10/09/2012
• Est. Priority Date: 05/27/2010
• Status: Expired due to Fees

• Current Assignee: Tenneco Automotive Operating Company Incorporated (Apollo Global Management, Inc.)
• Original Assignee: Tenneco Automotive Operating Company Incorporated (Apollo Global Management, Inc.)
• Inventors: Olivier, Keith G., Custer, Thomas
• Primary Examiner(s): SAINT SURIN, JACQUES M
• Application Number:
  US12/788,882
• Publication Number:
  US 20110290025A1
• Time in Patent Office: 866 Days
• Field of Search: 735/87, 735/88, 736/27, 737/88, 738/01, 738/04, 736/02
• US Class Current: 73/587
• CPC Class Codes: F01N 3/2828 Ceramic multi-channel monoliths, e.g. honeycombs
• CPC Class Codes: G01N 2291/0258 Structural degradation, e.g. fatigue of composites, ageing of oils
• CPC Class Codes: G01N 29/14 using acoustic emission techniques echo of particles G01N29/046; measuring mechanical vibrations or acoustic waves in solids in general G01H1/00

Abstract

A method of detecting a fracture as it occurs in a component during a manufacturing process includes positioning an acoustic sensor in acoustic communication with the component. A manufacturing process is performed while the acoustic sensor remains in acoustic communication with the component. A signal indicative of acoustic emissions from the component during the manufacturing process is provided to a controller where it is determined whether the component has fractured based on the signal.

Claims

1. A method of detecting a fracture as it occurs in a component during a manufacturing process, the method comprising:

positioning an acoustic sensor in acoustic communication with the component;

performing a manufacturing process while the acoustic sensor remains in acoustic communication with the component;

providing a signal indicative of acoustic emissions from the component during the manufacturing process to a controller; and

determining whether the component has fractured by comparing the magnitude of the signal to a predetermined maximum.

2. The method of claim 1 further including biasedly engaging the acoustic sensor with the component.

3. The method of claim 2 further including positioning a transducer in contact with a metallic wave guide to define the acoustic sensor.

4. The method of claim 3 further including providing the wave guide with a convex surface and engaging the convex surface with the component.

5. The method of claim 4 further including automatically dispensing an acoustic couplant at the interface of the wave guide and the component.

6. The method of claim 1 further including indicating that a fracture has occurred when the signal magnitude exceeds the predetermined maximum.

7. The method of claim 1 wherein the manufacturing process includes inserting a catalytic converter substrate into a housing.

8. The method of claim 7 further including reducing an outer diameter of the housing while providing the acoustic emissions signal.

9. The method of claim 7 wherein the acoustic sensor is positioned in contact with the substrate.

10. The method of claim 9 wherein the substrate includes a ceramic material.

11. A method of detecting a fracture in a component of an exhaust treatment device as it occurs during a manufacturing process, the method comprising:

positioning an acoustic sensor in acoustic communication with the exhaust treatment device;

performing a manufacturing process on the exhaust treatment device while the acoustic sensor remains in acoustic communication with the exhaust treatment device;

outputting a signal from the acoustic sensor indicative of acoustic emissions from the exhaust treatment device during the manufacturing process;

comparing the signal to a predetermined value; and

determining whether the exhaust treatment device has fractured based on the comparison.

12. The method of claim 11 further including biasedly engaging the acoustic sensor with the exhaust treatment device.

13. The method of claim 12 wherein the sensor is biasedly engaged with the exhaust treatment device prior to initiation of the manufacturing process.

14. The method of claim 11 wherein the manufacturing process includes axially translating a ceramic substrate into a housing.

15. The method of claim 11 wherein the manufacturing process includes radially reducing the size of the housing.

16. The method of claim 11 wherein the manufacturing process includes transporting a component of the exhaust treatment device between manufacturing work stations.

17. The method of claim 11 further including mounting the acoustic sensor to a slide and moving the sensor relative to the exhaust treatment device independent of a clamping device acting on the exhaust treatment device.